manufacturing science & engineering

VISVESVARAYA TECHNOLOGICAL UNIVERSITY, BELGAUM SCHEME OF TEACHING AND EXAMINATION FOR

M.TECH.-MANUFACTURING SCIENCE & ENGINEERING (MSE)

I Semester CREDIT BASED

Subject Code

Name of the Subject

Teaching hours/week

Duration of Exam in Hours

Marks for

Total Marks

CREDITS Lecture

Practical / Field Work / Assignment/

Tutorials

I.A. Exam

14 MSE 11 Quality & Reliability Engineering 4 2 3 50 100 150 4

14 MSE 12 Advanced Foundry Technology 4 2 3 50 100 150 4

14 MSE 13 Theory of Metal Forming 4 2 3 50 100 150 4

14 MSE 14 Advanced Materials & Processing 4 2 3 50 100 150 4

14 MSE 15x Elective - I 4 2 3 50 100 150 4

14MSE16 Lab Component -- 3 3 25 50 75 2

14MSE17 Seminar -- 3 -- 25 -- 25 1

Total 20 13 15 300 550 850 23

Elective – I

Sub. Code Name of the Subject 14 MSE 151 Applied Probability and Statistics 14 MSE 152 Composite Materials 14 MSE 153 Theory of Metal Cutting 14 MSE 154 Computer Integrated Manufacturing &

Automation 14MSE 155 Quantitative Techniques in Decision Making 14MSE156 Operations Management



II Semester CREDIT BASED

Subject Code

Name of the Subject

Teaching hours/week

Duration of Exam in Hours

Marks for

Total Marks

CREDITS Lecture

Practical / Field Work / Assignment/

Tutorials

I.A. Exam

14 MSE 21 Industrial Robotics 4 2 3 50 100 150 4

14 MSE 22 Non-Traditional Machining Processes 4 2 3 50 100 150 4

14 MSE 23 Non-Destructive Testing 4 2 3 50 100 150 4

14 MSE 24 Surface Treatment & Finishing 4 2 3 50 100 150 4

14 MSE 25x Elective-II 4 2 3 50 100 150 4

14MSE26 Lab Component 3 3 25 50 75 2

14MSE27 Seminar -- 3 -- 25 -- 25 1

**Project Phase-I(6 week Duration) -- -- -- -- -- -- --

Total 20 13 15 300 550 850 23

** Between the II Semester and III Semester, after availing a vocation of 2 weeks.

Elective – II Sub. Code Name of the Subject

14 MSE 251 Simulation & Modeling of Manufacturing Systems 14 MSE 252 Finite Element Methods 14 MSE 253 Agile manufacturing 14 MSE 254 Advanced Joining Processes 14 MSE 255 Agile anufacturing



III Semester: INTERNSHIP CREDIT BASED

Course Code Subject

No. of Hrs./Week Duration of the Exam in Hours

Marks for Total Marks CREDITS

Lecture Practical / Field Work

I.A. Exam

14MSE31

Seminar / Presentation on Internship (After 8 weeks from the date of commencement)

- - - 25 - 25 1

14MSE 32

Report on Internship - - - 75 75 15

14MSE 33

Evaluation and Viva-voce - - - – 50 50 4

Total - - - 25 125 150 20


M.TECH.-MANUFACTURING SCIENCE & ENGINEERING (MSE) IV Semester CREDIT BASED

Subject Code Subject

No. of Hrs./Week Duration of

Exam in Hours

Marks for Total

Marks CREDITS Lecture

Field Work / Assignment /

Tutorials I.A. Exam

14MSE41 Tool Design 4 -- 3 50 100 150 4

14MSE42X

Elective-III 4 - 3 50 100 150 4

14MSE43 Evaluation of Project Phase-II - - - 25 - 25 1

14MSE44 Evaluation of Project Phase-III - - - 25 - 25 1

14MSE45 Evaluation of Project Work and Viva-voce

– - 3 - 100+100 200 18

Total 12 07 09 150 400 550 28

Grand Total (I to IV Sem.) : 2400 Marks; 94 Credits

Elective – III

Sub. Code Name of the Subject 14 MSE 421 Industrial Design & Ergonomics 14 MSE 422 Advanced Manufacturing Practices 14 MSE 423 Advanced Fluid Power Systems 14 MSE 424 Project Management 14 MSE 425 Nano Technology

Note:

1) Project Phase – I : 6 weeks duration shall be carried out between II and III Semesters. Candidates in consultation with the guides shall carryout literature

survey / visit to Industries to finalise the topic of dissertation. . 2) Project Phase – II : 16 weeks duration. 3 days for project work in a week during III Semester. Evaluation shall be taken during the first two weeks of the

IV Semester. Total Marks shall be 25. 3) Project Phase – III : 24 weeks duration in IV Semester. Evaluation shall be taken up during the middle of IV Semester. At the end of the Semester

Project Work Evaluation and Viva-Voce Examinations shall be conducted. Total Marks shall be 250 (Phase I Evaluation:25 Marks, Phase –II Evaluation: 25 Marks, Project Evaluation marks by Internal Examiner( guide): 50, Project Evaluation marks by External Examiner: 50, marks for external and 100 for viva-voce).

Marks of Evaluation of Project:

• The I.A. Marks of Project Phase – II & III shall be sent to the University along with Project Work report at the end of the Semester.

4) During the final viva, students have to submit all the reports. 5) The Project Valuation and Viva-Voce will be conducted by a committee consisting of the following:

a) Head of the Department (Chairman) b) Guide c) Two Examiners appointed by the university. (out of two external examiners at least one should be present).

QUALITY AND RELIABILITY ENGINEERING

Subject Code : 14 MSE 11 IA Marks : 50 No. of Lecture Hours/Week : 04 Exam Hours : 03 Total No. of Lecture Hours : 52 Exam Marks : 100

Basic Concepts: Definitions of quality and Reliability, Parameters and Characteristics, Quality control, statistical Quality Control, Reliability concepts. Concepts in Probability and Statistics : Events, Sample Space, Probability rules, Conditional probability, Dependent and Independent Events, Application of Probability concepts in Quality Control, Problems

Introduction to Probability Distributions : Normal, Poisson and Binomial distribution. Control Charts : Variable Chart – X Bar chart, R-chart and Sigma chart. Attribute Chart : P – Chart, nP Chart, C-Chart and U – Chart.

Acceptance Sampling: Fundamentals of acceptance sampling, types of acceptance sampling, O.C Curve, AQL, LTPD, AOQL.

Failure Data Analysis : Introduction, Failure Data, Quantitative measures, MTTF, MTBF, Bathtub Curve, Mean Life, Life Testing, Problems, Introduction to Failure Mode and Effect Analysis.

System Reliability: Series, parallel and mixed configuration, Block diagram concept, r- out-of-n structure solving problems using mathematical models.

Reliability Improvement and Allocation : Difficulty in achieving reliability, Methods for improving reliability during design, Different techniques available to improve reliability, Optimization, Reliability-Cost trade off, Prediction and Analysis, Problems.

Maintainability and Availability: Introduction, Formulas, Techniques available to improve maintainability and availability trade-off among reliability, maintainability and availability, Simple problems REFERENCE BOOKS:

1. Quality Planning and Analysis - Tata McGraw - Juran, J.M and Gryna, F.M. - Hill publishing Coimpany Ltd., New Delhi, India – 1982.

2. Maintainability and Reliability Handbook of Reliability Engineering and Management - Editors – Ireson. W.G. and Cooms - C.F. McGraw - Hill Book Company Inc. – 1988.

3. Concepts in Reliability Engineering- Srinath L S - Affiliated East-West Press Private Limited, New Delhi, India. – 1985. 4. An Introduction to Reliability and Maintainability Engineering - TMH Charles Ebeling - Tata Mcgraw

Hill – 2000. Reliability Engineering - A K Govil - Prentice Hall – 1981

ADVANCED FOUNDRY TECHNOLOGY


Solidification of Casting: Concept of solidification of metals. Homogenous and heterogeneous nucleation. Growth mechanism. Solidification of pure metals and alloys. Mechanism of columnar and dendritic growth. Coring or Segregation. Solidification time and Chvorinov's rule. Concept of progressive and directional solidifications. Principles of Casting and Risering: Purpose of the gating system. Components of the gating System and its functions. Design of the gating System. Different types of gates. Gating ratio and its functions. Definition and functions of the riser. Types of risers and their application. Design of the riser - its shape. Size and location. Use of insulating material and exothermic compounds in risers. Design of Casting: Factors to be considered in casting design. Design consideration in pattern making, moulding techniques and core making and assembly. Cooling stresses and hot spots in casting and modification in casting geometry to overcome them. Casting Quality Control: Casting defects and factors responsible for them. Different inspection and testing methods to evaluate the casting. Quality control activities in a foundry. Salvaging methods of defective casting. Furnace Technology: Study of various furnaces used in foundry, construction and operation of crucible and hearth furnaces. Resistance, Arc and Induction furnaces-their construction. Operation and application. Heat treatment furnaces and drying ovens used in foundry. Gray Cast - Iron Foundry Practice: Chemical Composition and structure of gray cast iron. Moulding, gating and risering techniques. Melting of gray cast iron in Cupola and induction furnace. Inoculation of gray cast iron. Application of gray cast iron castings. Malleable Cast Iron: Chemical composition and structure of White-heart and black-heart malleable cast iron. Melting malleabilisation heat treatment and application of malleable cast iron. Ductile Cast Iron: Chemical composition and structure of ductile cast iron. Melting and spherodisation treatment. Inoculation of 'ductj)e iron Properties and application of ductiles iron casting. Steel Casting Practice: Common steel casting, their composition,structure and properties. Melting and refining of steel. Gating andrisering of steel castings cleaning of steel castings. Aluminium Foundry Practice : Composition, properties and application of common aluminium alloy casting. Melting and casting of AI-alloys. Gating and risering of AI-alloy casting. Copper alloy Foundry Practice: General characteristics of common cast copper alloys. Melting and casting of copper alloys. Gating and risering of cu-alloy castings. Foundry Mechanization and Modernization: Introduction to modernization. Mechanization of foundry and its advantages. Mechanization of sand plant, moulding and core making mechanization in melting, pouring and shakeout units. Material handling equipments and conveyor systems. Brief sketches and description of layouts of job. Captive and mechanized foundries. REFERENCE BOOKS:

1. Principle of metal casting - Heine, et. al - Tata-McGraw-HiII Publication - 2003. 2. A test book of FoundryTechnology - Lal, M. Khanna, P.O - DhanpatRai & Sons Publication. 3. Foundry Technology - Beelely, P.R. – Butterworth.

THEORY OF METAL FORMING

Subject Code : 14 MSE 13 IA Marks : 50

No. of Lecture Hours/Week : 04 Exam Hours : 03

Total No. of Lecture Hours : 52 Exam Marks : 100

Introduction to Forming process: Introduction to metal forming, Effect of temperature on forming process-hot working, cold working. Effect of Metallurgical structure, Effect of speed of deformation work of Plastic deformation, Friction in forming operation . Forging: Classification, various stages during forging, Forging equipment, brief description, deformation in compression, forging defects. Residual stresses in forging. Rolling of Metals: Classification, forces and geometrical relationships in rolling. Variables in Rolling: Deformation in rolling, Defects in rolled products, Residual stresses in rolled products. Torque and Horsepower.

Extrusion: Classification, Extrusion equipment, variables in extrusion, Deformation in extrusion, Extrusion defects, Work done in extrusion.

Drawing: Principles of Rod and wire drawing, variables in wire drawing, Residual stresses in rod, wire and tube drawing, Defects in Rod and wire drawing.

Sheet Metal Forming: Introduction, Forming methods, shearing and Blanking, Bending, stretch forming, Deep drawing, redrawing operations, Defects in formed products. REFERENCE BOOKS:

1. Mechanical MetalIurgy - Dieter G.E. - Mc Graw Hill Publications. 2. Principles of Metal Working - R.Rowe - Amold London – 1965. 3. Metals Handbook – ASM - Volume II -.ASM 4. Fundamentals of working of Metals - Sach G. - Pergamon Press.

ADVANCED MATERIALS AND PROCESSING

Subject Code : 14 MPY 14 IA Marks : 50



Classification and characteristics: Metals, Ceramics, Polymers and composites. General properties and structure: Atoms, molecules bonds in solids, Crystalline - Defects in Metallic structure, Dislocations and plastic deformation - Strengthening mechanism - grain size, dislocation - Cold work, precipitation hardening, dispersion hardening - phase reactions, fatigue and Creep behavior.

Ferrous Alloys: iron carbon equilibrium diagrams - Steels and cast irons - properties, structure, composition and applications transformation hardening in steels - TIT diagrams - Heat treatment processes - Effect of alloying elements - High alloy steels, Stainless steel types, tool Steels, Manganese steels, heat resistant steels, HSLA, Maraging steels.

Non Ferrous alloys: AlIoys of copper, Aluminum, nickel, magnesium, titanium, lead, tin, Zinc - composition, heat treatment, structure, properties and application. Polymers and polymerizations: Structure and properties of thermoplastics and thermo sets – Engineering Applications - property modifications - Mechanical and thermal behavior – processing methods.

Ceramics : Nature and structure of Ceramics - Refractory Abrasives glasses - glass ceramics - Advanced ceramics -processing methods.

Composites : Definition - classification and characteristics of composite materials - Volume fraction - laminated composites particulate composites, fibrous composites - Types of reinforcements, their shape and size - production and properties of fiber reinforced plastics, Metal Matrix composites and ceramic matrix composites - Applications.

Processing of Polymers: composites, ceramics - thermal spraying - Ion beam machining diamond coating techniques-tribological Applications.

REFERENCE BOOKS:

1. Engineering Metallurgy - Raymond and Higgens - ELBS/EA 2. Introduction to Material Science and Engineering - James.F.Shackleford - Mc Millan, NY - 7th edition. 3. Powder Metallurgy-Metals Hand Book -ASM, USA - Vol.7, 1974. 4. Composite Materials - Science and Engineering - Chawla K.K. , Springer - Verlag, Newyork - 2nd edition,

1998. 5. Cast Metal Matrix Composites ASM Metals Hand Book - P.K. Rohagti - VI5. 6. Elements of Material science and Engineering - Van Vlack L.H. - Addison Wesley, NY - 1989.

Elective – I

APPLIED PROBABILITY AND STATISTICS


Introduction to statistics: Statistical Thinking, Collecting data, Statistical Modeling Frame work, measure of central tendency and variance, Importance of Data summary and Display, Tabular and Graphical display. Discrete Random Variables and Probability distribution: Discrete Random variables, Probability distributions and Probability mass functions, Cumulative distribution functions, Mean and Variance of a discrete random variable, discrete uniform distribution, Binominal distribution, Hyper Geometric distribution, Poisson distribution, Applications. Continuous Random Variables and Probability Distributions: Continuous random variables, Probability distributions and probability density functions, cumulative distribution functions, Mean and Variance of a continuous random variable, uniform distribution, Normal distribution, Normal approximation to Binominal and Poisson distribution, Exponential distribution. Testing of Hypothesis: Estimation theory, Hypothesis testing, Inference on the mean of a population (variance known and unknown), Inference on the variance of a normal population, Inference on a population proportion, Testing for Goodness of Fit, Inference for a difference in Means, Variances known, Inference for a difference in means of two normal distributions, Variances unknown, Inference on the Variances of two normal populations, Inference on two population proportions. Simple Linear Regressions and Correlation: Simple Linear Regression, Properties of Least square Estimators and Estimation of variances, Transformations to a straight line, Correlation. Multiple linear regressions : Multiple linear regressions model, least square estimation of parameters, Matrix approach to multiple linear regression, properties of least square estimators and estimation of variance.

TEXT BOOKS:

1. Applied statistics and Probability for Engineers – Douglas C Montgomery, George C Runger, 2nd Edn, John Wiley and Sons, ISBN-0-471-17027-5, 1999.

2. Statistics for Management, Richard I Levin, David S Rubin, 6th Edn, Prentice Hall India, ISBN-81-203-0893-X.

REFERENCES: 1. Probability and Statistics in Engineering - William W Hines, Douglas C Montgomery - John Wiley and

Sons - 2nd Edn,. 2. Business Statistics for Management and Economics - Daniel, Terrell - Houghton Mifflin Company - 6th

Edn, ISBN-0-395-62835-0. 3. Probability and Statistics - by Walpole & Mayer - MacMillan Publishing Company - 1989.

COMPOSITE MATERIALS


Introduction to Composite Materials: Definition, Classification, Types of matrices & reinforcements, characteristics & selection, Fiber composites, laminated composites, particulate composites, prepegs, sandwich construction. Micro Mechanical Analysis of a Lamina: Introduction, Evaluation of the four elastic moduli – Rule of mixture, Macro mechanics of a lamina: Hooke’s law for different types of materials, number of elastic constants, Laminate code, Failure criterion. Manufacturing: Lay Up and Curing – open and closed mould processing – Hand lay up techniques Bag moulding and filament winding. Pultrusion, Pulforming, Thermoforming, Injection moulding, Cutting, Machining and joining, tooling, Quality assurance Introduction, material qualification, types of defects, NDT methods. Fabrication of Composites: Cutting, machining, drilling, mechanical fasteners & addesive bonding joining computer aided design manufacturing tooling fabrication equipment Design of Fibre Reinforced Composite Structures: Introduction, Composite structural design, Design criteria, Laminate design, Mathematical analysis of the laminate, Design of composite stiffeners. Application Developments – Aircrafts, missiles, space hardware, automobile, electrical and electronics, marine, recreational and sports equipment-future potential of composites. Metal Matrix Composites: Re-inforcement materials, types, Characteristics & Selection, base metals-selection, applications. Powder metullury technique, liquid metallurgy technique TEXT BOOKS:

1. Composite Materials Handbook - Mein Schwartz - Mc Graw Hill Book Company - 1984. 2. Mechanics of Composite Materials - Autar K.Kaw - CRC Press New York - 1st edi, 1997.

THEORY OF METAL CUTTING


Mechanics of Metal Cutting: Mechanism of chip formation, Orthogonal & Oblique cutting, types of chips, built-up edge, Determination of shear plane angle, forces on the chips, forces in orthogonal cutting, Merchant circle diagram and analysis, Theory of Lee & Shaffer, co-efficient of friction, power & energy relationship, velocity relationship, shear-strain, factors affecting forces and power, problems.

Geometry of Cutting Tools: Single point and multi point cutting tools, tools nomenclature, tool point reference systems, tool angle specifications –ISO and ASA systems, conversion from one system to another. Recommended tool angles, Effect of cutting parameters on tool geometry.

Tool Materials and Their Properties: Characteristics of tool materials, types of tool materials – carbon tool steels, high speed steels, cast alloys, cemented carbides, ceramics, diamonds, SIALON, CBN, UCON, recommended cutting speeds for the above tools, discussion on steels,air, water, oil hardening of tools and their applications.

Measurement of Cutting Forces: Reasons for measuring cutting forces, Classification of cutting force dynamometers – mechanical, hydraulic, pneumatic, optical, inductance, piezoelectric, and strain gage type dynamometers, Dynamometers for lathe, drilling, and milling, Calibration of dynamometers.

Tool Wear, Tool Life: Mechanisms of tool wear, Sudden & gradual wear, crater wear, flank wear, tool failure criteria, tool life equations, effect of process parameters on tool life, tool life tests, conventional & accelerated tool wear measurement, machinability index

Thermal Aspects in Metal Cutting: Heat sources in metal cutting, temperature in chip formation, temperature distribution, experimental determination of tool temperatures. Cutting fluids: Basic actions of cutting fluids, properties of cutting fluids, selection of cutting fluids, application of cutting fluids, filtration of fluids, recommended cutting fluids. Economics of Machining: Introduction, elements of total production cost, optimum cutting speed and tool life for minimum cost, optimum cutting speed and tool life for maximum production, problems. REFRENCE BOOKS

1. Metal Cutting Principles - M.C. Shaw - Oxford Publication – 1985. 2. Fundamentals of metal cutting & Machine Tools - by B.L.Juneja & G.S – Sekhar - Wiley Eastern. 3. Metal Cutting - V.C.Venkatesh & S.Chandrasekhanan - Pantice Hall – 1991.

Metal Cutting - Dr. B.J.Ranganath -Vikas Publications

COMPUTER INTEGRATED MANUFACTURING AND AUTOMATION

Subject Code : 14 MSE 154 IA Marks : 50



Production Development Through CIM: Computers in Industrial manufacturing, Product cycle & Production development cycle, Introduction of CAD/CAM & CIM, sequential and concurrent engineering, soft and hard prototyping. Computer Process Monitoring: Process control methods, direct digital control, supervisory computer control, steady state optimal control, on line search strategies, adaptive control. Computer Aided Quality Control: The computer in Q.C, automated inspection principles and methods, Contact inspection methods, non-contact inspection methods, machine vision system, optical inspection method, sensors, coordinate, measuring machine, Computer-Aided testing, Integration of CAQL with CAD/CAM. Computer Integrated Manufacturing: Fundamentals of CAD/CAM, Computerized Manufacturing planning systems, shop floor control & automatic identification techniques. Computer Network for manufacturing and the future automated factor. Detroit type of Automation: Flow lines, Transfer Mechanisms, work pattern transfer, Different methods, & Problems. Analysis of Automated flow lines: Analysis of transfer lines without storage with storage buffer single stage, Double stage, Multistage with problems, Automated assembly systems, Design for automated assembly, parts feeding devices, analysis of Multi station assembly machine, Analysis of Single stage assembly machine, Automated Material Handling Storage: Material functions, types of material handling equipment, analysis of material handling systems, design of system, conveyor system, automated guided vehicle systems, automated storage/retrieval systems, caroused storage systems work in process storage, interfacing handling & storage with manufacturing.

REFERENCE BOOKS:

1. CAD/CAM - Zimmers & Grover – PHI. 2. CAD/CAM/CIM - P.Radhakrishna - New Age International - 2nd edition. 3. Automation, Production systems & Computer Aided Manufacturing - M.P. Grover - Prentice Hall - 1984. 4. CAD/CAM - Zeid – Mc-Graw Hill - 2005. 5. CAD/CAM - P.N.Rao - TMH.- 2 nd edition, 2004. 6. Robotics for Engineering - Koren.Y - Mc-Graw Hill - 1985. 7. Robert vision & Sensory Controls - Rooks B. - North Holland. - (ed) vol-3

QUANTITATIVE TECHNIQUES IN DECISION MAKING

Sub Code : 14 MSE 155 IA Marks : 50 No. of Lecture Hrs/week : 04 Exam Hours : 03 Total Lecture Hrs : 52 Exam Marks : 100 Introduction : Applications of statistics in managerial decision making, The basic vocabulary of statistics, Types of variables, Data collection – primary and secondary data, the methods of collecting data, Measures of central tendency , Measure of dispersion, Skewness and Kurtosis, Measures of a population, Probability - basic concepts, types, rules of probability, Baye’s theorem; Random variables, Probability distributions - Binomial, Poisson, and Normal. Linear Programming Problem: Formulation of L.P.P., Solution of L.P.P. - graphical method, simplex method, special cases; Concept of duality, Conversion of primal LP problems into dual LP problems and vice versa, Solution of L.P.P. by dual simplex method, Sensitivity analysis in the solution of L.P problems. Transportation and Assignment Problems: Structure of transportation problem and various methods to find I.B.F.S., Optimality test of transportation problems by MODI method, Solution of unbalanced transportation problems and maximization problems, degeneracy in the solution of transportation problems; Assignment problems and solution by Hungarian method, Traveling Salesman problem. Decision Making under Uncertainty: Alternative criteria for decision under uncertainty, Bayesian approach Theory of Games: Terminology involved, Types of games, Solution of mixed strategy games by dominance rule, algebraic method, graphical method, and by linear programming approach. Network Analysis: Network construction, Analysis techniques – PERT and CPM, Determination of critical path, Computation of ES, EF, LS, LF, TF and FF, Crashing of a project, Resource scheduling and leveling in a project. Waiting Line : Basic structure of queuing systems and characteristics, Expressions for M/M/l and M/M/c queuing models. Simulation of Management Systems: Steps in building a simulation model, Advantages and disadvantages of simulation, the applications of simulation to managerial decision making, Monte Carlo Simulation, Waiting line and Inventory simulation models. REFERENCE BOOKS:

1. Quantitative Techniques for Management – David M. Levine, Timothy C. Krehbiel, Mark L. Berenson, Barry Render, Ralph M. Stair, Jr., Michael E. Hanna, Pearson, Latest Edition.

2. Operations Research – Prem Kumar Gupta, Dr. D. S. Hira, S. Chand, Latest Edition. 3. Quantitative Techniques for Managerial Decisions – Srivastava, U.K. - New Age International Private

Limited, Latest Edition

OPERATIONS MANAGEMENT

Sub Code : 10 MSE 156 IA Marks : 50 No. of Lecture Hrs/week : 04 Exam Hours : 03 Total Lecture Hrs : 52 Exam Marks : 100

Operations Planning Concepts: Introduction, Operations Functions in Organizations, Historical development, Framework for managing operations, The trend: Information and Non-manufacturing systems, Operations management, Factors affecting productivity, International dimensions of productivity, The environment of operations, Production systems decisions- a look ahead.

Operations Decision Making : Introduction, Management as a science, Characteristics of decisions, Framework for decision making, Decision methodology, Decision Tree Problems, Economic models-Break Analysis in operations, P/V ratio, Statistical models. System Design and Capacity : Introduction, Manufacturing and service systems, Design and systems capacity, Capacity planning.

Forecasting Demand: Forecasting objectives and uses, Forecasting variables, Opinion and Judgmental methods, Time series methods, Moving Average methods , Exponential smoothing, Trend adjusted Exponential Smoothing, Regression and correlation methods, Application and control of forecasts-Mean Absolute Deviation, BIAS, Tracking Signal.

Aggregate Planning and Master Scheduling: Introduction- planning and scheduling, Objectives of aggregate planning, Three Pure Strategies, Aggregate planning methods, Master scheduling objectives, Master scheduling methods.

Material and Capacity Requirements Planning : Overview: MRP and CRP, MRP: Underlying concepts, System parameters, MRP logic, System refinements, Capacity management, CRP activities.

Scheduling and Controlling Production Activities: Introduction, PAC, Objectives and Data requirements, Loading –Finite and Infinite Scheduling methodology, priority sequencing, capacity control. Single Machine Scheduling : Concept, measures of performance, SPT rule, Weighted SPT rule, EDD rule. Flow –Shop Scheduling: Introduction, Johnson’s rule for ‘n’ jobs on 2 and 3 machines, CDS heuristic. Job-Shop Scheduling: Types of schedules, Heuristic procedure, scheduling 2 jobs on ‘m’ machines.

Text Books: 1. Monks, J.G., Operations Management, McGraw-Hill International Editions, 1987. 2. Productions & operations management by Adam & Ebert. 3. Pannerselvam. R., Production and Operations Management, PHI. 4. Chase Jacobs Aquilano, Operations Management for Competitive Advantages,10th

Edition, TMH

References: 1. Buffa, Modern Production/Operations Management, Wiely Eastern Ltd. 2. Chary, S.N., Production and Operations Management, Tata-McGraw Hill. 3. Operations management by James Dilworth. 4. Lee J Karjewski and Larry P Ritzman, Operations Management – strategy and Analysis, 6th Edn, Pearson

Education Asia 5. B J Ranganath , System Dynamics by - I K International Publishing house Pvt. Ltd.

Laboratory Exercises

14 MSE 16 Perform any Eight / Ten experiments :

1. Determination of Chip reduction co-efficient (reciprocal of chip thickness ratio) during single point turning. 2. Forces measurements during orthogonal turning. 3. Estimation of Power required during orthogonal turning. 4. Torque and Thrust measurement during drilling. 5. Determination of cutting forces during milling using Milling tool dynamometer 6. Measurement of Chip tool Interface temperature during turning using thermocouple technique. 7. Study the variation of surface roughness with different speed and feed during plain milling operation on flat

surface. 8. Study of capstan lathe and its tooling and prepare a tool layout & job as per given drawing. 9. To prepare metallic samples for metallographic examination and to study the principle & construction of the

Metallurgical Microscope. 10. Study of Microstructure and Hardening of steel in different medium and cooling rates. 11. Effect of Carbon percentage on the hardness of Steel. 12. CNC milling- Writing and execution of part program for contour milling.

II SEMESTER INDUSTRIAL ROBOTICS

( Subject Code : 14 MSE 21 IA Marks : 50 No. of Lecture Hours/Week : 04 Exam Hours : 03 Total No. of Lecture Hours : 52 Exam Marks : 100

FUNDAMENTAL CONCEPTS OF ROBOTICS: History, present status and future trends, Robotics. Robot, Definition. Robotics Systems and Robot Anatomy, Specification of Robotics. Resolution, Repeatability and Accuracy of a Manipulator ROBOT DRIVES: Power transmission systems and control Robot drive mechanisms, hydraulic-electric-penumatic drives. Mechanical transmission method – Rotary-to-Rotary motion conversion. Rotary-to-linear motion conversion end effectors – types-grip pind problem Remote-Centered compliance Devices-Control of Actuators in Robotic Mechanisms. SENSORS AND INTELLIGENT ROBOTS: Sensory devices – Non-optical-Position sensors – Optical position sensors – velocity sensors – proximity sensors: Contact and non-contact type-Touch and slip sensors – Force and Torque Sensors – AI and Robotics. COMPUTER VISION FOR ROBOTICS SYSTEMS: Robot vision systems – Imaging components – Image representation – Hardware aspects-Picture coding – Object Recognition and Categorization- Visual inspection – software considerations – applications – commercial – Robotics vision systems. COMPUTER CONSIDERATIONS FOR ROBOTIC SYSTEMS: Computer architecture for robts, hardware, Computational elements in robotic applications – Robot programming – sample programs path planning – Robot’s computer system. TRANSFORMATIONS AND KINEMATICS: Homogeneous Co-ordinates – Co-ordinate Reference Frames – Homogeneous Transformations for the manipulator – the forward and inverse probleme of manipulator kinematics – Motion generation – Manipulator dynamics – Jacobian in terms of D.H.Matrices controller architecture. ROBOT CELL DESIGN AND CONTROL: Specifications of Commerical Robots – Robot Design and Process specifications – motor selection in the design of a robotic joint – Robot Cell layouts – Economic and Social aspects of robotics. APPLICATIONS OF ROBOTS: Capabilities of Robots – Robotics Applications – Obstacle avoidance – Robotics in India – The future of Robotics TEXT BOOKS:

1. Robotics Engineering An integrated approach - Richard D Klafter, Thomas A Chmielewski, Michael Negin – Prentice Hall of India Pvt. Ltd. - Eastern Economy Edition, 1989.

2. Robotics: Control Sensing, Vision, intelligence - Fu KS Gomaler R C, Lee C S G - McGraw Hill Book Co. - 1987.

REFERENCE BOOKS:

1. Handbook of Industrial Robotics - Shuman Y. Nof - John Wiley & Sons, New York - 1985. 2. Robotics Technology and Flexible Automation - Deb SR - McGraw Hill BookCo. - 1994.

NON-TRADITIONAL MACHINING PROCESSES

Subject Code : 14 MSE 22 IA Marks : 50 No. of Lecture Hours/Week

: 04 Exam Hours : 03

Total No. of Lecture Hours

: 52 Exam Marks : 100

Introduction : Need for non-traditional machining processes. Processes selection c1assification on – comparative study of different processes. Mechanical Process: Ultrasonic Machining-Definition-Mechanism of metal elements of the process- Tool feed mechanism. theories of mechanics of causing effect of parameter applications.

Abrasive Jet Machining: Principles - parameters of the process applications-advantages and advantages.

Thermal Metal Removal Process: Electric discharge machining Principle of operation – mechanism of meta removal basic EDM circuitry-spark erosion get Analysis of relaxation type of circuit material removal rate in relaxation circuits- critical resistance parameters in Ro Circuit-Die electric fluids-Electrodes for sparl surface finish. Applications. Electro Chemical and Chemical Processes: Electro chemical machining (ECM) Classification ECM process-principle of ECM Chemistry of the ECM parameters of the processes-determination of the metal removal rate - dynamics of ECM process-Hydrodynamics of ECM process-polarization-.Tool Design-advantages and disadvantages - applications. Electro Chemical Grinding-Electro Chemical holding Electrochemical deburring. Chemical Machining: Introduction-fundamental principle types of chemical machining Maskants- Etchenes- Advantages and disadvantages-applications. Plasma arc Machining: Introduction-Plasma-Generation of Plasma and equipment Mechanism of metals removal, PAN parameters-process characteristics - type of torches applications.

Electron Beam Machining (EBM): Introduction-Equipment for production of Electron beam - Theory of electron beam machining Thermal & Non thermal types characteristics - applications.

Laser Beam Machining (LBM): Introduction-principle of generation of lasers Equipment and Machining procedure-Types of Lasers-Process characteristics-advantages and limitations-applications Ion Beam Machining: Introduction-Mechanism of metal removal and associated equipment-process characteristics applications High Velocity Forming Process: introduction - development of specific process selection-comparison of conventional and high velocity forming methods - Types of high velocity forming methods- explosion forming process-elector hydraulics forming magnetic pulse forming. REFERENCE BOOKS:

1. New technology Institution of Engineers - Bhattacharya - India 2. Production Technology - HMT - Tata Mc Graw Hill - ISBN-10; 0070964432 3. Modern Machining Process - P.C Pandy & H.S. Shan - Tata McGraw Hill - ISBN:

0070965536 - Publishing Date: Feb-80 4. Metals Hand Book - ASM - Vol-3. 5. High Velocity Forming of Metals - F.M Wilson - ASTME Pretice Hall. 6. Modern Manufacturing Method - Adithan - New Age International (p) Limited - ISBN: 8122408176, 2007. 7. Modern Machining Processes - P.K. Mishra - Narosa Publishing House, New Delhi - 1997.

NON-DESTRUCTIVE TESTING




: 52 Exam Marks

: 100

Introduction to ND Testing: Selection of ND methods, visual inspection, leak testing, Liquid penetration inspection, its advantages and limitation. Magnetic Particle Inspection: Methods of generating magnetic field, types of magnetic particles and suspension liquids steps in inspection – application and limitations

. Eddy Current Inspection: principles, operation variables, procedure, inspection coils, and detectable discounts by the method. Microwave Inspection: Microwave holography, applications and limitations. Ultrasonic inspection: Basic equipment characteristics of ultrasonic waves, variables inspection, inspection methods pulse echo A,B,C scans transmission, resonance techniques, transducer elements couplets, search units, contact types and immersion types inspection standards-standard reference blocks, Radiography Inspection: principles, radiation source X-rays and gamma rays, X-ray-tube, radio graphic films, neutron radiography, Thermal inspection principles, equipment inspection methods applications. Optical Holography: Basics of Holography, recording and reconstruction - Acoustical Holography: systems and techniques applications.Indian standards for NDT.

REFERENCE BOOKS:

1. Non Destructive Testing - Mc Gonnagle JJ – Garden and reach New York. 2. Non Destructive Evolution and Quality Control - volume 17 of metals hand book 9 edition Asia internal

1989. The Testing instruction of Engineering materials - Davis H.E Troxel G.E wiskovil C.T - McGraw hill

SURFACE TREATMENT & FINISHING





Fundamentals of Electro plating, galvanizing, Hot dip metal coating, thin coating, thin coating, chromium plating, Nickel plating. Vacuum coating, FVD & CVD metal spraying - Methods, surface preparation, mechanical Properties of sprayed metals, plasma coating.

Plastic coating of metal - PVC coating Spherodising process details, phosphate coating - mechanism of formation. Testing of surface coating-methods.

Heat treatment methods, Aneleaing, Normalizing, Tempering, Case hardening methods, flame hardening sub zero treatment.

Heat treatment methods for gears, spindles, cutting tools. Advanced coating technologies: Hard facing, electro deposition technique, nanocoatings, coating characterization REFERENCE BOOKS:

1. Surface preparations & finishes for Metals - James A Murphy - McGraw Hill. 2. Principles of metal surface treatment and protection - Pergamon Press Gabe, David Russell - Description,

Oxford ; New York - 2d ed., 1978. 3. Handbook of metal treatment and testing - John wiley & sons. 4. Heat Treatment of Metals – Zakrov - MlR Publications. 5. Metals Hand Book – ASM.

SIMULATION AND MODELING OF MANUFACTURING SYSTEMS .





Principle of Computer Modelling And Simulation: Monte Carlo simulation. Nature of computer- modeling and simulation. Limitations of simulation, areas of applications. System and Environment: Components of a system -discrete and continuous systems, Models of a system -a variety of modeling approaches. Discrete Event Simulation: Concepts in discrete event simulation, manual simulation using event scheduling, single channel queue, too server queue , simulation of inventory problem. Statistical Models in Simulation: Discrete distributions, continuous distributions. Random Number Generation: Techniques for generating random numbers- Mid square method -the mod product method -Constant multiplier technique -Additive congruential method -Linear congruential method -Tests for random numbers -The Kolmogorov-Smimov test -the Chi-square test. *** Ivica Cmkovic, Ulfaskluna and Annita borsen Dohlgvist Publisher Artechhouse. Random Variable Generation: Inversion transforms technique-exponential distribution. uniform distribution, weibul distribution, continuous distribution, generating approximate normal variates-Erlang distribution. Empirical Discrete Distribution: Discrete uniform -distribution poisson distribution -geometric distribution -acceptance -rejection technique for Poisson distribution gamma distribution. Design and Evaluation Of Simulation Experiments: variance reduction techniques -antithetic variables, variables-verification and validation of simulation models. Simulation Software: Selection of simulation software, simulation packages. TEXT BOOKS:

1. Discrete Event System Simulation - Jerry Banks & .John S Carson II - Prentice Hall Inc.-1984. 2. Systems Simulation - Gordan. G. - Prentice Hall India Ltd - 1991.

REFERENCE BOOKS:

1. System Simulation with Digital Computer - Nusing Deo - Prentice Hall of India - 1979. 2. Computer Simulation and Modeling - Francis Neelamkovil - John Wilely & Sons - 1987. 3. Simulation Modeling with Pascal - Rath M.Davis & Robert M O Keefe - Prentice Hall Inc. - 1989.

FINITE ELEMENT METHODS

Subject Code : 14MSE 254 IA Marks : 50 No. of Lecture Hours/Week : 04 Exam Hours : 03 Total No. of Lecture Hours : 52 Exam Marks : 100

Introduction: Equations of equilibrium, stress-strain relations for 2-D and 3-D, Potential energy and equilibrium, Boundary conditions, Von Misses Stresses FEM for 1-D Problems: General procedure for FEA, Raleigh Ritz method, Galerkin Approach, shape functions, stiffness matrix, load vectors, temperature effects, Applications of boundary conditions using elimination, penalty and multi-constraint approaches, Application problems – 1-D bar element. Trusses and beams

FEM for 2-D Problems: Shape functions, stiffness matrix, strain matrix, load vectors for CST Elements and application problems

FEM for Axisymmetric Problems: Axisymmetric formulation, triangular elements, PE approach, Body force term, application problems

FEM for Scalar Field Problems: 1-D Steady state heat transfer, torsion, potential flow and fluid flow in ducts and application problems Dynamic Analysis: Equations of motion for dynamic problems --consistent and lumped mass matrices --formulation of element mass matrices free vibration and forced vibration problems formulation, REFERENCE BOOKS:

1. Introduction to Finite Elements in Engineering - Tirupathi R. Chandrupatla, Ashok D Belegundu - Prentice Hall India Pvt. Ltd., New Delhi – Third Edition, 2003.

2. Concepts and Applications of finite Element Analysis - Cook R.D, Malkus D.S & Plesha M.E - John Wiley & Sons - 1989.

3. Applied Finite Element Analysis - Segerlind L .J - John Wiley & Sons Edition - 1984. 4. The Finite Element Method in Engineering - Rao SS - Pergomon Press, Oxford - 2nd Edition, 1984. 5. Finite Element Procedures in Engineering Analysis - Bathe K .J - prentice Hall, NewJersey -1982. 6. Energy and Finite Element Methods in Structural mechanics - Shames III & Dym C L - Wiley

eastern ltd – 1995.

AGILE MANUFACTURING





Introduction - What is agile Manufacturing? - Competitive environment of the future the business case for agile manufacturing conceptual ftame work for agile manufacturing. Four Core Concepts: Strategy driven approach - integrating organization, people technology interdisciplinary design methodology. Agile Manufacturing and Change Management: The change implications. Post failures in advanced manufacturing, changes on the way, traditional managernent accounting, paradigm, investment appraisal, product costing - performance, measurement and control systems, Traditiosal organization, control technological and design paradigms traditional problems in workplace- organizational issues - role of technology. Agile Manufacturing Enterprise Design: Agile manufacturing - enterprise design.. system concepts as the basic manufacturing theory - joint technical & organizational design and a model for the design of agile manufacturing enterprise, enterprise design process insights into design processes, what is interdisciplinary design, Main issues - simple design example. Skill & Knowledge Enhancing Technologies for Agile Manufacturing : Skill and Knowledge enhancing Technologies - scheduling - technology design strategic-Design Concepts. Design and Skill of Knowledge enhancing Technologies for machine tool systems - Historical overview, Lessons, problems and Future development. REFERENCE BOOKS:

1. Agile manufacturing - Forging new Frontiers - Paul T. Kidd - Addison Wesley Publication -1994. 2. Agile Manufacturing – Proceedings of International Conference - Dr. M.P Chowdiah (Editor) – Tata Mc

Graw Hill Publications - 1996. 3. On agile manufacturing - Tata McGraw Hill Publications -1996 4. Agile manufacturing - Forging Neat Furniture's - Paul T Kidd – Addition Wesley Pub – 1994. 5. World Class Manufacturing - Paul T Kidd - Washington: National - 1994

ADVANCED JOINING PROCESSES


Distortion - methods to avoid distortion. Stresses in Joint Design. Welding and Cladding of dissimilar materials, overlaying and surfacing.

Electro Slag, Welding Electron Beam Welding, Plasma arc Welding, Laser Beam Welding, Explosion Welding, Diffusion Welding, Ultrasonic Welding, Friction welding and Thermit welding. Advanced soldering and Brazing processes different types. Welding of plastics. Inspection of Welds: Destructive techniques like Tensile, Bend, Nick break, Impact & Hardness. Non-Destructive techniques like 'X' rays, Ultrasonic, Magnetic particle, Dye Penetrant, Gamma ray inspection. Welding Symbols- Need for, Representing the welds, Basic weld symbols, Location of Weld, Supplementary symbols, Dimensions of welds, Examples Welding Design - Introduction, Principles of sound welding design, Welding joint design. Welding positions, Allowable strengths of welds, under steady loads. Quality Control in Welding - Introduction, Quality assurance v/s Quality control, Weld quality, Discontinuities in welds, their causes and remedies and Quality conflicts. Computer-Aided Welding Design - Introduction. Principles of sound welding design, Wilding joint design. Welding positions. Allowable strengths: of welds. 1D1der steady loads. Weld throat thickness. Solved and um solved examples.

REFERENCE BOOKS: 1. Welding Engineering Handbook - A.W.S. 2. Welding Engineering - Rossi - McGraw Hill. 3. Advanced Welding processes - Nikodaco & Shansky - MIR Publications. 4. Welding Technology - O.P. Khanna 5. Welding for Engineers - Udin, Funk & Wulf

AGILE MANUFACTURING

Subject Code : 14 MSE255 IA Marks : 50 No. of Lecture Hours/Week




Introduction - What is agile Manufacturing? - Competitive environment of the future the business case for agile manufacturing conceptual ftame work for agile manufacturing. Four Core Concepts: Strategy driven approach - integrating organization, people technology interdisciplinary design methodology. Agile Manufacturing and Change Management: The change implications. Post failures in advanced manufacturing, changes on the way, traditional managernent accounting, paradigm, investment appraisal, product costing - performance, measurement and control systems, Traditiosal organization, control technological and design paradigms traditional problems in workplace- organizational issues - role of technology. Agile Manufacturing Enterprise Design: Agile manufacturing - enterprise design.. system concepts as the basic manufacturing theory - joint technical & organizational design and a model for the design of agile manufacturing enterprise, enterprise design process insights into design processes, what is interdisciplinary design, Main issues - simple design example. Skill & Knowledge Enhancing Technologies for Agile Manufacturing : Skill and Knowledge enhancing Technologies - scheduling - technology design strategic-Design Concepts. Design and Skill of Knowledge enhancing Technologies for machine tool systems - Historical overview, Lessons, problems and Future development. REFERENCE BOOKS:

1. Agile manufacturing - Forging new Frontiers - Paul T. Kidd - Addison Wesley Publication -1994. 2. Agile Manufacturing – Proceedings of International Conference - Dr. M.P Chowdiah (Editor) – Tata Mc

Graw Hill Publications - 1996. 3. On agile manufacturing - Tata McGraw Hill Publications -1996 4. Agile manufacturing - Forging Neat Furniture's - Paul T Kidd – Addition Wesley Pub – 1994. 5. World Class Manufacturing - Paul T Kidd - Washington: National - 1994

Laboratory Exercises

14 MSE 26

01. Study of pick and place Robot- basic components, configuration, work volume

02. Experiments with Robot. Kit for minimum four assembly activities and programming

03. Programming of robots by manual, lead through and off line methods

04. Programming languages for stacking of objects in increasing or decreasing size. Palletizing operations, assembly and inspection operation etc.

05. To become acquainted with the operation of a revolute-type 6 DOF robot. To program a robotic system using

a teaching pendant and a high level programming language. Emphasis is made on the constraints associated when positioning and orienting an object within a 3-D space The practical includes point-to-point tasks and continuous robot motion.

IV SEMISTER

TOOL DESIGN

Subject Code : 14MSE41 IA Marks : 50 No. of Lecture Hours/Week




Tool-design Methods: Introduction, the design procedure, drafting and design techniques in tooling drawing Tool-making Practices:Introduction, tools of the tool maker, hand finishing and polishing, screws and dowels, hole location, jig-boring practice, installation of drilling bushings, punch and die bushings, punch and die manufacture, EDM, EDM for cavity applications, tracer and duplicating mills for cavity applications, low-melting tool materials. Tooling Materials and Heat Treatment:Introduction, properties of materials, ferrous tooling materials, non-ferrous tooling materials, non-metallic tooling materials, heat treatment and tool design. Design of Cutting Tools: Introduction, the metal cutting process, revision of metal cutting tools-single point cutting tools, milling cutters, drills and drilling, reamers, taps. Selection of carbide tools, determining the insert thickness for carbide tools. Design of Tools for Inspection and Gauging: Introduction, work piece quality criteria, principles of gauging, types of gages and their applications, amplification and magnification of error, gage tolerances, selection of material for gages, indicating gages, automatic gages, gauging positionally tolerance parts, problems. Locating and Clamping Methods: Introduction, basic principle of location, locating methods and devices, basic principle of clamping. Design of Drill Jigs: Introduction, types of drill jigs, general considerations in the design of drill jigs, drill bushings, methods of construction, drill jigs and modem manufacturing. Design of Fixtures:Introduction, types of fixtures, fixtures and economics.

Design of Press-working Tools:Power presses, cutting operations, types of die-cutting operations - and their design, evolution of blanking and progressive blanking Design of Sheet Metal Bending, Forming and Drawing Dies: Introduction, bending dies, forming dies, drawing dies. Evolution of a draw die, progressive diesand selection of progressive dies. Strip development for progressive dies, evolution of progressivedies, examples of progressive dies. Extrusion dies, drop forging dies and auxiliary tools, problems. Tool Design for Joining Processes:Introduction, tooling for physical joining processes, tooling for soldering and brazing, tooling for mechanical joining processes, problems. Tooling for Casting:Introduction, tooling for sand casting, shell moulding, metal moulding and die-casting, problems.

Tool Design for NC Machine Tools :Revision of NC control, fixture design for NC machine tools, cutting tools and tool-holding methods, automatic tool charigers and tool positioners. Plastics as Tooling Materials : Introduction, plastics commonly used as tooling materials, application. of epoxy plastic tools, construction methods, metal forming operations with Urethane dies, calculating forces for Urethane

pressure pads, problems. TEXT BOOKS:

1. Tool Design - Cyril Donaldson, GH Lecain and VC Goold - TMH Publishing Co Ltd., New Delhi, - 3rd editions, 2000.

2. Fundamentals of Tool Design – ASTME - PHI (P) Ltd., New Delhi -1983. REFERENCE BOOKS:

1. Cutting Tool Design - Rodin - Mir publications -1968. 2. Metal cutting & Tool Design - Arshinov - Mir Publishers , Moscow – 1970. 3. Press working of metals – Hinman - McGraw Hill – 1950.

ELECTIVE -III

INDUSTRIAL DESIGN & ERGONOMICS

Subject Code : 14MSE421 IA Marks : 50 No. of Lecture Hours/Week




Introduction: An approach to industrial design - elements of design structure for industrial design in engineering application in modem manufacturing systems. Ergonomics and Industrial Design: Introduction - general approach to the man-machine relationship-workstation design-working position. Control and Displays: shapes and sizes of various controls and displays-multiple displays and control situations - design of major controls in automobiles, machine tools etc., - design of furniture design of instruments. Ergonomics and Production: Ergonomics and product design ergonomics in automated systems-expert systems for ergonomic design, Anthropomorphic data and its applications in ergonomic design limitations of anthropomorphic data - use of computerized database. Visual Effects of Line and Form: The mechanics of seeing psychology of seeing, general influences of lined and form. Colour: colour and light - colour and objects - colour and the eye colour consistency - colour terms - reactions to colour and colour continuation - colour on engineering equipments. Aesthetic Concepts: Concept of unity - concept of order with variety - concept of purpose style and environment - Aesthetic expressions. Style-components of style - house style, observations style in capital goods. Industrial Design in Practice: General design - specifying design equipments - rating the importance of industrial design – industrial design in the design process. TEXT BOOKS:

1. Industrial design for Engineers - Mayall W.H. - London Cliffee Books Ltd. - 1988. 2. Applied Ergonomics Hand Book - Brien Shakel (Edited) - Butterworth Scientific, London – 1988.

ADVANCED MANUFACTURING PRACTICES




: 52 Exam Marks

: 100

Need of CPC for a company, what CPC can do, CPC-getting the right tool. JIT – Introduction – The spread of JIT Movement, some definitions of JIT, core Japanese practices of JIT, Creating continuous Flow Manufacture, Enabling JIT to occur, Basic elements of JIT, Benefits of JIT.

Just in Time Production – Primary purpose, profit through cost reduction, Elimination of over production, Quality control, Quality Assurance, Respect for Humanity, Flexible work Force, JIT Production Adapting to changing production Quantities, process layout for shortened lead Times, Standardization of operation, Automation. Sequence and Scheduling Used by Suppliers: Monthly and daily Information. Sequenced withdrawal system by sequenced schedule table, problems and counter measures in applying the Kanban system to sub contractors.

Toyota Production System-The philosophy of TPS, Basic Frame work of TPS, Kanbans. Determining the Number of Kanbans in Toyota Production System. a) Kanban Number under Constant Quantity Withdrawal System. b) Constant Cycle, Non-constant Quantity Withdrawal System.

Supplier Kanban and the Sequence Schedule for Use by Suppliers. a) Later Replenishment System by Kanban. b) Sequenced Withdrawal System. c) Circulation of the Supplier Kanban within Toyota.

Production Smoothing in TPS Production Planning Production Smoothing Adaptability to Demand Fluctuations Sequencing Method for the Mixed Model Assembly Line to Realize Smoothed Production of Goal.

Just-in-Time Production with Total Quality Control just in time concept, cutting lot sizes, cutting set-up times, cutting purchase order costs, the JIT cause-Effect chain, Scrap/Quality Improvements, Motivational effects, Responsibility effects, small Group improvement Activities, withdrawal of Buffer Inventory, the total Quality Control Concept.

Total Quality Control-Introduction -Total Quality Control concepts, responsibility, learning from the west, TQC concepts categorized, Goals, Habit of improvement, perfection, Basics, process control, Easy to see Quality control as facilitator, small lot sizes, Housekeeping, Less than full capacity scheduling, Daily machine checking, Techniques and Aids, Exposure of problems, Fool proof Devices, Tools of Analysis, QC Circles, TQC in Japanese-owned US Electronics plant, TQC in Japanese-owned Automotive plants.

Plant Configurations: Introduction -ultimate lant configuration, job shop Fabrication, Frame Welding, Forming Frame parts from Tubing, Dedicated production lines, overlapped production, the daily schedule, Forward Linkage by means of Kanban, physical merger of processes, Adjacency, mixed Models, Automated production Lines, Pseudo Robots, Robots, CAD and Manufacturing, Conveyors and stacker Cranes, Automatic Quality Monitoring

TEXT BOOKS: 1. Japanese Manufacturing Techniques - Richard Schonberger - Pearson Higher Education - ISBN:

0029291003 1982 2. Just In Time Manufacturing – Kargoanker (manual). 3. Wind-chill reference manual.

REFERENCE BOOKS: 1. An Integrated Approach To Just In Time - Yasuhiro Monden - Toyota Production system. 2. Lean Thinking - James Womack - Simon & Schuster Adult - ISBN: 0743249275, 2003. 3. The machine that changed the World - James P. Womack, Daniel T Jones, and Daniel Roos - The story of

Lean production – by– Harper Perennial edition published -1991.

ADVANCED FLUID POWER SYSTEMS

Subject Code : 14MSE423

IA Marks : 50

No. of Lecture Hours/Week




Introduction: Pascal Law, Advantages of Fluid Power, Applications of Fluid Power, Components of a Fluid Power. Hydraulic Power Unit: Introduction, Pumping Theory, Pump Classification, Gear Pumps, (Vane Pumps- simple, balanced & pressure compensated vane pump, Vane design) Piston Pumps- Radial, Axial (Bent axis & Swash plate), Pump Performance, Pump Noise, Ripple in pumps.

Hydraulic Actuators: Linear actuator- cylinders, Mechanics of Hydraulic cylinder loading, limited rotation hydraulic actuator, cylinder cushioning, Gear, Vane & Piston motor, Motor performance, Hydrostatic transmission Power Controlling Elements – Valves : i) Directional Control Valves – Classification, 2/2, 3/2,4/2 & 4/3 ways Dcv’s, Different Centre configurations in 4/3 way valves, actuation of DCV’s, Indirect actuation, Valve Lap – Lap during Stationary and during switching. ii) Pressure Control Valves: Classification, opening & Closing Pressure difference, Cracking Pressure, Pressure Relief Valve – Simple & Compound type, Pressure reducing valve, sequence, unloading & Counter balance valve, Pressure switches. iii) Flow Control valves – Fixed throttle, Variable throttle, Pressure Compensation principles, pressure compensated Flow control valve – Reducing & Relief type. iv) Check valve, Pilot operated check valve. Hydraulic Circuit Design & Analysis: Control of Single & double acting cylinder, Regeneration circuit, cylinder sequencing & Synchronizing circuit. Speed control of cylinder & Motors, Analysis of Hydraulic system with frictional losses, Accumulators &accumulator circuits. Pneumatic System: Introduction, – Generation of compressed air, air receiver, servicing FRL unit, Air filter, pressure regulation, lubricator, Pneumatic cylinder & air motor – different types of cylinder, cushion assembly. Cylinder performance. Pneumatic Valve: Directional control valves, impulse valve, Quick exhaust valve, shuttle valve, Twin pressure valve, Time delay valve, Pneumatic Circuit & Logic Circuits: - Control of single and double acting cylinder, impulse operation, speed control, sequencing, Pneumatic Vacuum system AND,OR, NOT, NAND, NOR, YES Function, Logic circuits design using shuttle valve & twin pressure valve, Binary Arithmetic, logic & Boolean Algebra, use of kannaugh veitch map for pneumatic circuit design.

Electrical Control in Fluid Power: Contactors, & Switches, Relays, Limit switch, Electro hydraulic & Electro Pneumatic Circuits, Simple Cylinder reciprocation, interlocking using relays, Proximity switches, application of proximity switches, Time dependent will dependent and travel dependent circuits. REFERENCE BOOKS:

1. Fluid Power with Application - Anthony Esposito - Peason Education - 5th edition.

2. Oil hydraulics -Principles & maintenance - S.R. Majumdar - Tata M C Graw Hill 3. Components & Application - Bosch Rexroth didactic - Hydraulics Trainer - vol 1. Publication 4. Pneumatic System, Principles and Maintenance - S.R. Majumdar - Tata M C Graw Hill Publication. 5. Pneumatics: Theory and Applications - Bosch Rexroth didactic - Publication 6. Electro Pneumatics - Bosch Rexroth didactic - Vol. 2, Publication.

PROJECT MANAGEMENT

Subject Code : 14MSE 424 IA Marks : 50 No. of Lecture Hours/Week : 04 Exam Hours : 03 Total No. of Lecture Hours : 52 Exam Marks : 100

Introduction: Projects, types of projects- public and private projects, project organization, structure and processes. Identification of Investment Opportunities, Market and Demand Analysis – Technical Analysis – Investment Outlay.

Means of Financing: Profitability and Breakeven Analysis – Cash Flows of Projects – Tax factor in investment Analysis – Interest – Compounding and Discounting.

Appraisal Criteria and Selection of Investment: Cost of Capital – Analysis of Risk – Financial Projection, Social Cost Benefit Analysis.

Manpower Management in Projects: Functional Approach to Manpower Management – The Element of decision Process – Project Team Concepts – Field Autonomy – Policies Governing Projects.

Networks Technique in Project Management: PERT/CPM Analysis – Administrative aspects of Capital Investment.

REFERENCE BOOKS:

1. Projects\”– Appraisal, preparation, budgeting and implementation Prasannachandra – Tata McGraw

Hill. 2. Hand book of Project Management– Dennis Lock. 3. Project Management – Dennis lock.

NANO TECHNOLOGY

Sub Code :14 MSE 425 IA Marks : 50 No. of Lecture Hrs/week : 04 Exam Hours : 03 Total Lecture Hrs : 52 Exam Marks : 100

Metal based nanocomposites- Metal-Oxide or Metal-Ceramic composites, Different aspects of their preparation techniques and their final properties and functionality. Metal-metal nanocomposites, some simple preparation techniques and their new electrical and magnetic properties. Design of Super hard materials- Super hard nanocomposites, its designing and improvements of mechanical properties. Nanofiller synthesis, applications, Polymer nanocomposites, particulate and fibre modified nanocomposites, matrices and fibres, polymer- filler interphase, pull- out strength, effect of various treatments. Mechanics of polymer nanocomposites, Interfacial adhesion and charecterisation, factors influencing the performance of nanocomposites, physical and functional properties. Nano composite fabrication, matrices, methods, additives, moulding processes. Polymer-carbon nanotubes based composites, processing methods and characterization using SEM, XRD, TEM Characterization of Polymer nanotubes based composites for Mechanical, Electrical and Thermal Properties and their applications - Polymer / nanofillers (metallic nanopowders) systems, Rheological measurements, processing characteristics Testing of nanocomposites, Thermal analysis such as TGA, TMA, DSC, DMTA REFERENCE BOOKS:

1. Text Book of Polymer Science - Fred W. Billimeyer, Jr - Wiley Interscience Publication - third edition , 1994.

2. Polymer Science and Technology - Joel R. Fried - Prentice- Hall, Inc. Englewood Cliffs, N. J., USA - 2000. 3. New Developments and Technology -Hand book of Elastomers - (Eds. A. K. Bhowmic and H. C.

Stephense), Marcel - Dekker Inc., New York - 1995. 4. Polymer Blends - D. R. Paul and S. Newman - Academic Press, New York - 1978. 5. Short Fibre Reinforced Thermoplastics - M. J. Folkes - John Wiley, New York - 1982.

Nanocomposites Science and Technology Physical Properties of Carbon Nanotubes - P. M. Ajayan, L.S. Schadler, P. V. Braun , R. Saito, Carbon Nanotubes (Carbon, Vol 33) - M. Endo, S. Iijima, M.S. Dresselhaus

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